future of the electric car

8/7/2019 Future of the Electric Car

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1 2006 Ridley Engineering Inc.

The Future of the Electric CarThe Future of the Electric Car

Dr. Ray RidleyDr. Ray Ridley

President, Ridley Engineering Inc.President, Ridley Engineering Inc.

Ridley Engineering UKRidley Engineering UK

Publisher, Switching Power MagazinePublisher, Switching Power Magazine

www.ridleyengineering.comwww.ridleyengineering.com


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GMGMs EV1 1998s EV1 1998--20042004

Collaboration between Hughes and GMCollaboration between Hughes and GM

50 to 100 mile range50 to 100 mile rangegreat fun to drive. All owners loved itgreat fun to drive. All owners loved it

IGBT power systemIGBT power system

ContactlessContactless chargercharger

$1.3bn program to build 1000 in response to CA clean air mandat$1.3bn program to build 1000 in response to CA clean air mandatee FixedFixed--term leasesterm leases


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EV1 Charging SystemEV1 Charging System

Split transformer designSplit transformer design

All about marketing safety imageAll about marketing safety image

Amazing power electronics achievementAmazing power electronics achievement

The wrong way to do itThe wrong way to do itfar too complex and costlyfar too complex and costly Charging stations were difficult to maintain and unreliableCharging stations were difficult to maintain and unreliable


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ElectricalGeneration

33%

ElectricalTransmission

93%

BatteryCycle

85%

Drive

80%

EnergySource

FossilNuclear

Renewable

EV Overall Efficiency = 21%

ExtractionRefining

?

TransportationStorage

90%

Automobile

10-40%

Gasoline Overall Efficiency = 9-36%

Electric Vehicle EfficiencyElectric Vehicle Efficiency


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Cost of FuelCost of Fuel

($ per 100 miles)

$2.40

$8.80

$0

$4

$8

$12

Electric

GasolineConventional

US($2/gal)


Europe

($10/gal)

$44.00


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What killed the EV1 program?What killed the EV1 program? Removal of government mandates in 2001Removal of government mandates in 2001

Poor driving rangePoor driving range Long charging timesLong charging times

Infrastructure of chargersInfrastructure of chargers

Lack of funding with no profits in sight for GMLack of funding with no profits in sight for GM

Modern business mentalityModern business mentality

Low gas pricesLow gas prices

Fuel usage efficiencyFuel usage efficiency



The EV1 FuneralThe EV1 Funeral

December 2004December 2004



Toyota RAV4 EV

out of production

Chevy S10 EV

out of production

Honda EV Plus

out of production

GM EV1out of production

Ford Ranger EVout of production

Chrysler EPIC EVout of production

EV1 ContemporariesEV1 Contemporaries

Were these programs an engineering failure?Were these programs an engineering failure?

No, they were the first step toward miniaturized powerNo, they were the first step toward miniaturized power

electronics and costelectronics and cost--reduced electric propulsion, essential forreduced electric propulsion, essential for

hybrids and the next generation of electric vehicleshybrids and the next generation of electric vehicles

They were a business failure in the modern contextThey were a business failure in the modern context



EV1 SuitabilityEV1 Suitability Short distance drivingShort distance driving

Commuting to work



We need Hummers!

www.hummerart.com



TheThe GreenGreen HummerHummer

Hydrogen poweredHydrogen powered

About 50 miles per tankAbout 50 miles per tank

No refueling infrastructure existsNo refueling infrastructure exists

Note: no fuel transfer is taking place in pictureNote: no fuel transfer is taking place in picture



The Hydrogen EconomyThe Hydrogen Economy

Beyond the Hummer, does it make sense?Beyond the Hummer, does it make sense? Note: no refueling is taking place here, either.Note: no refueling is taking place here, either.



No one allowed in fueling enclosure without:

Lab Coat

Nomex Overalls

Gloves

Eye Protection

Shutoff required 25 feet from nozzle

Refueling RealityRefueling Reality

Robotic Fueling Arm

BMW AG approved for press purpose

BMW AG approved for press purpose




33%

HydrogenGeneration

50%

CompressionTransportation

Storage

90%?

Fuel Cell

50%

EnergySource

FossilNuclear

Renewable Overall Efficiency = 5.9%

Drive

80%

Hydrogen EfficiencyHydrogen Efficiency



Cost for Fuel($ per 100 miles)

$2.40

$4.40

$8.80

$10.08

$0

$4

$8

$12

Electric

GasolineHybrid

HydrogenFuel Cell


*

* Does not include Transportation and Infrastructure cost of Hydrogen

Hydrogen CostsHydrogen Costs




33%

ElectricalTransmission

93%

Battery

85%

Drive

80%

HydrogenGeneration

50%

CompressionTransportation

Storage

90%?

Fuel Cell

50%

EV Efficiency = 21%

EnergySource

FossilNuclear

Renewable

Hydrogen Efficiency = 5.9%

Drive

80%

Hydrogen vs. Electric EfficiencyHydrogen vs. Electric Efficiency



Toyota RAV 4 EV

EPA rating:30 kWh/100 miles

Energy use per mile:0.30 kWh/mi

Honda FCX FCEV

EPA rating:

50 mi/kg H2Energy to make H2:63 kWh/kg (based onStuart Energy electrolyzer)

Energy use per mile:1.26 kWh/mi

Real World NumbersReal World Numbers



The Technical ChallengesThe Technical Challenges

for Hydrogenfor Hydrogen

Increase efficiency by 400% to match EVIncrease efficiency by 400% to match EV

Extreme high volume production of hydrogenExtreme high volume production of hydrogen Where will the energy come from?Where will the energy come from?

Safe storage at 5Safe storage at 5--10,00010,000 psipsi

Safe fuel dispensing at 5Safe fuel dispensing at 5--10,00010,000 psipsi Fuel tank volumeFuel tank volume

Reduce fuel cell cost by factor of 10Reduce fuel cell cost by factor of 10

Increase fuel cell efficiencyIncrease fuel cell efficiency

Transportation and infrastructureTransportation and infrastructure

Remember, hydrogen is not a natural fuel resourceRemember, hydrogen is not a natural fuel resourceit is anit is anenergy storage systemenergy storage system



The One Benefit of HydrogenThe One Benefit of Hydrogen

Rapid refuelingRapid refuelingequivalent to 3 MWequivalent to 3 MW



Hydrogen for AviationHydrogen for Aviation

The last time it wasThe last time it was usedused, things didn, things didnt go wellt go wellwaswas

hydrogen the problem?hydrogen the problem?



TheThe CryoplaneCryoplane

Liquid hydrogen is the only hope of getting enough fuel onLiquid hydrogen is the only hope of getting enough fuel on

board. Even then, fuel tank capacity must be 3.5 times biggerboard. Even then, fuel tank capacity must be 3.5 times biggerthan gasoline tanks for the same energy storage.than gasoline tanks for the same energy storage.



The Future Electric VehicleThe Future Electric Vehicle

New battery technologyNew battery technology

New car frames and materialsNew car frames and materials

New economics of world fuel suppliesNew economics of world fuel supplies



AC PropulsionAC Propulsions Lis Li--IonIon tZerotZero

0060 in 3.9 seconds60 in 3.9 seconds

Top speed 85 mphTop speed 85 mph 300 mile range300 mile range

Cost of fuel $4Cost of fuel $4 -- 66

Charging infrastructure already in place (electrical grid)Charging infrastructure already in place (electrical grid) Designed by AlanDesigned by Alan CocconiCocconi


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AC PropulsionAC Propulsions Lis Li--IonIon tZerotZero

tZero vs Ferrari F355 1/8 mile tZero vs Corvette

tZero vs Porche Carrera 4


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LiLi--Ion BatteriesIon Batteries

6,800 cells give 330-420 V at 500 A

P El i f h Z


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S1

S2

S3 S5

S4 S6

Battery

K1

K2

K2EMI Line Filter

Traction Motor

3-Phase Inverter (10 kHz)

Reductive Charger

Power Electronics of thePower Electronics of the tZerotZero

66--pulse bidirectional inverter/rectifier for unity PFC charging, mpulse bidirectional inverter/rectifier for unity PFC charging, motorotor

drive, and regenerative brakingdrive, and regenerative braking Traction motor acts as boost inductor for 20 kW chargingTraction motor acts as boost inductor for 20 kW charging

If you have an alternate energy sourceIf you have an alternate energy sourcewindmill, solar, geothermal,windmill, solar, geothermal,

biomass, etc.biomass, etc.fill up the car yourself!fill up the car yourself!

Car can run as emergency generator for home use or grid supportCar can run as emergency generator for home use or grid support


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Twelve TO-247 IGBTs are paralleled for each power switch

Complete power electronics package with cooling fan

Power Electronics of thePower Electronics of the tZerotZero


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200200--hp Traction Motorhp Traction Motor

Total weight = 50 lbsTotal weight = 50 lbs

Efficiency = 90%Efficiency = 90%


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Commercial ImplementationCommercial Implementation

Volvo 3CC concept car with AC Propulsion drive and LiVolvo 3CC concept car with AC Propulsion drive and Li--IonIonbatteries with a 180batteries with a 180--mile rangemile range

Car never made available to the publicCar never made available to the public


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TheTheVenturiVenturi FetishFetish

Custom built for 25 customersCustom built for 25 customers 200 mile range with AC Propulsion Drive200 mile range with AC Propulsion Drive

105 mph top speed105 mph top speed

00--60 mph in 4.5 seconds60 mph in 4.5 seconds $500,000 price tag (Half the price of the EV1!)$500,000 price tag (Half the price of the EV1!)


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If you like exorbitantly priced, two-seater vehicles that don't go very far or very

fast and must subsequently remain out of commission for hours at a time, theVenturi Fetish just may be the perfect vehicle for you.

-- Thom Blackett autobytel.com

Top Ten Auto Show Duds: What Were They Thinking?

The Narrow-Minded View


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Charging RatesCharging Rates

FutureFuture EVsEVs, estimate about 1 min/mile charge time at, estimate about 1 min/mile charge time at

10 kW10 kW 10 miles in 1 minute at 100 kW (100 miles in 1010 miles in 1 minute at 100 kW (100 miles in 10

minutes)minutes)

200 miles in 20 minutes at 100 kW200 miles in 20 minutes at 100 kW

Habits must change for this to succeedHabits must change for this to succeed


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Li Ion Battery Development

0

50

100

150

200

1994 1996 1998 2000 2002

Wh/kg

0

1

2

3

4

$/Wh

LiLi--Ion Battery PerformanceIon Battery Performance

Batteries for 200 mile range about $18kBatteries for 200 mile range about $18k Current fuel cell cost about $1Current fuel cell cost about $1--2000 per kW2000 per kW

(100 kW needed,(100 kW needed, tZerotZero is 150 kW)is 150 kW)


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What are the Priorities?What are the Priorities?

Reduced dependence on oilReduced dependence on oil

Reduced cost of carsReduced cost of cars Increased shortIncreased short--term and longterm and long--term profits forterm profits for

carmakerscarmakers

Lower cost of drivingLower cost of driving Uncompromised performanceUncompromised performancerange, speed, fuelingrange, speed, fueling

time.time.

You cannot have it all!You cannot have it all!


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0

10

20

30

40

50

1950 1960 1970 1980 1990 2000

Gb

oil discovery

oil production

World Oil

The Oil WILL Run OutThe Oil WILL Run Out

in our childrenin our childrens lifetime if nothing is done.s lifetime if nothing is done.

New drilling will not make a significant difference.New drilling will not make a significant difference.

H d El iH d El t i


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Hydrogen vs. ElectricHydrogen vs. Electric

High power stations or fill at homeHigh power stations or fill at homeHydrogen fueling stationsHydrogen fueling stations

Government funding: $0Government funding: $0Government funding: $1.2Government funding: $1.2 bnbn

Reversible systemReversible systembattery backup,battery backup,selfself--charge from alternate sources,charge from alternate sources,

support of electrical grid.support of electrical grid.

Fast RefuelingFast Refueling

4 times lower fuel cost4 times lower fuel cost4 times pollution of EV4 times pollution of EV

Battery SizeBattery SizeFuel Tank Size >5x presentFuel Tank Size >5x present

Fire safety of LiFire safety of Li--IonIonFuel safety at 5Fuel safety at 5--1010 kpsikpsi

High Power OutletsHigh Power OutletsStorage and TransportationStorage and Transportation

21% Efficiency21% Efficiency5.9% Efficiency5.9% Efficiency

Batteries $18K (200 mi range)Batteries $18K (200 mi range)Fuel Cells $100k (100 hp)Fuel Cells $100k (100 hp)


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What must be done?What must be done?

Technological risks and challenges of hydrogen far exceed thoseTechnological risks and challenges of hydrogen far exceed those of the EVof the EV

Accelerated hybrid/electric development with emphasis on electriAccelerated hybrid/electric development with emphasis on electric storage andc storage andpluggable carspluggable cars

Drastic reduction of fuel consumptionDrastic reduction of fuel consumption

Research into battery technologyResearch into battery technology

Increased charging capabilityIncreased charging capability

Research into alternative energyResearch into alternative energy ReRe--education of the public about what they wanteducation of the public about what they want

Normal market forces of supply and demand will not alter our marNormal market forces of supply and demand will not alter our marketplace inketplace intime; legislative intervention is necessarytime; legislative intervention is necessary

There is a HUGE opportunity here for the power electronics indusThere is a HUGE opportunity here for the power electronics industry and thetry and theeconomyeconomywill we take it?will we take it?


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Government Involvement?Government Involvement?

Drastically reduce the hydrogen programDrastically reduce the hydrogen programredirect the $1.2redirect the $1.2 bnbn

into electric/hybridinto electric/hybrid

Provide incentive innovationProvide incentive innovationinvest in it, reward its success andinvest in it, reward its success and

protect our IPprotect our IP

Provide longProvide long--term incentives for car makersterm incentives for car makersbreak thebreak the makemakethe quarterthe quarter mentalitymentality


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Coming Soon to a Theatre Near You..Coming Soon to a Theatre Near You..

Who Killed the Electric Car?Who Killed the Electric Car?

A documentary about GMA documentary about GMs EV1s EV1

http://www.imdb.com/title/tt0489037/http://www.imdb.com/title/tt0489037/

future of the electric car

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